Harley-Davidson FLTR/ FLH/ FLHT/ FLHR EFI models 1995-2001 Variable Pressure Fuel Regulator Intallation manual

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Filed Under (Harley Davidson) by admin on 27-04-2012

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1 . Ensure vehicle runs correctly through all rpm ranges and idles correctly before attempting any work. It is highly recommended that a pressure / flow test be carried out before & after installation of the VariReg to determine fuel system condition . Stock HD 300 kPa / 44 psi, VariReg as delivered 360 kPa / 52 psi Note: In some countries gas stations do not “final filter” the fuel & therefore we recommend that the fuel filter canister be replaced every 15,000 klms (10,000 miles). Restriction of the fuel by way of a blocked or partially blocked filter will result in difficulty in tuning or failure to obtain satisfactory results during tuning. Should you experience difficulties in tuning, see Diagnosing fuel filter and pump faults 2. Remove air filter cover, air filter and backing plate. Check Throttle Position Sensor value at completely closed throttle as best performance will be obtained at the nominated settings. This will require backing off the idle screw and cold start idle actuator and screw adjustment as described in the workshop manual. The original T.P.S. values should be recorded for possible future reference. To set TPS values without the HD breakout box see VariReg TPS Setting for Harley-Davidsons The T.P.S. values must be set to 1995 – 1996 175 mV (+/- 25mV) 1997 – 2001 275 mV (+/- 25mV) Record the original TPS value here. ………………..mV YOU MUST ENSURE THROTTLE PLATES ARE COMPLETELY CLOSED AND NO BINDING EXISTS IN CABLES to obtain the correct value setting. 3. Reset idle screws to approximate previous settings, no need to start the engine. 4. Complete full or partial fuel tank removal as described in workshop manual. 5. Remove stock fuel pressure regulator as described in workshop manual and leave Horn removed from vehicle until after tuning, this will allow ease of access to the regulator

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Harley-Davidson MINI-TACH GAUGE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-04-2012

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1. Refer to the Service Manual and follow the instructions given to remove the Maxi-Fuse. For ALL models, WITHOUT Maxi-Fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. -J03119 1 of Gasoline can drain fr om the carb uretor fuel line when disconnected from fuel valve fitting. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00256a) 2. For carbureted models: Turn the fuel supply valve to OFF. Remove the fuel line from the valve. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 3. For ALL models: Follow the instructions in the Service Manual to remove the instrument console from the fuel tank. 4. See FUEL TANK: REMOVAL in the appropriate section (Carbureted or EFI Engine) of the Service Manual for instructions to remove the tank. 5. For all models EXCEPT FLHR or 1986 and later FL Softail models with Chrome Headlight Nacelle Kit (Part Number 67907-96): Follow the instructions in the Service Manual to remove the headlamp housing. For FLHR models, or Softail models WITH the Nacelle Kit: Follow the instructions in the Service Manual and the mini-tach bracket kit (purchased separately) to remove the handlebar shroud.

2004-2005 KTM 250/ 400/ 450/ 525 Side Panel Fuel Tank removal and Installation Instructions

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Filed Under (KTM) by admin on 22-01-2012

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1. Remove airbox cover. Drill stock rivet nut in frame tube through with a ¼” drill as shown in Photo 1. Drill completely through frame tube. We suggest you make a small guide hole in the top of the frame tube first so that you drill straight through the frame member and not come out the side of the frame tube. Photo 1 .Install Lower mounting bracket as shown in Photo 3 noting its orientation. Install the aluminum cone into the recess at the bottom of the stock airbox , then bolt the bracket on with the 6 x 70 mm bolt. Nylock nut threads to top of bolt on top of frame tube as shown in photo 2. Photo 3 2 3. Install the upper mounting bracket shown in Photo 4. Note that in either the MXC or the EXC installation four to six of the 6 x 18 mm fender washers should be installed between the bracket and the subframe. The counter-sunk hole should be positioned toward the rear wheel. Leave the bracket slightly loose until step 6. Photo 4 The best routing for the fuel line (Photo 5 & 6 ) requires drilling holes in the airbox. See Step 4 for hole locations. 4. Drill a 3/8″ hole at the front left corner of the airbox as shown in Photo 6. Make sure the location you choose will not result in the hole coming out behind the frame tube or into the rubber airbox boot. Be very careful drilling this hole.

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YAMAHA 1996-2003 Road Star BILLET TACH MOUNT KIT INSTALLATION MANUALS

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Filed Under (Yamaha) by admin on 12-01-2012

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Remove and retain the (4) chrome caps from the handlebar clamps. Remove and retain the (4) stock allen head bolts. This hardware will be re-used with the new Billet Tach Mount Kit. Carefully remove the stock handlebar clamps while supporting the handlebars. INSTALLATION: 2. Slide the Electronic Tachometer (#6) into the Billet Tach Mount (#2) and secure with the 10-24 X 1/4″ Socket Set Screw (#10) supplied. Carefully pull the tachometer wire harness through the larger hole in the Billet Tach Cup (#3) and secure the Billet Tach Cup with the 10-24 X 1/8″ Socket Set Screw supplied. (The additional holes in the tach cup are for air circulation). Attach the Billet Tach Mount to the Billet Handlebar Clamp (#1) with the two 10-24 X 1-3/4″ Socket Head Screws (#4) supplied. Install the Billet Tach Mount assembly with the four stock allen head bolts and chrome caps removed in step 1 above. Adjust handlebars to desired height and torque bolts to factory specs. WIRING INSTRUCTIONS: 3. Refer to FIG. #1 . Remove Seat. Disconnect negative cable from battery. Remove fuel tank retaining bolts. Raise fuel tank about 3″-4″ to expose the Left Side Ignition Coil. It is not necessary to completely remove the gas tank on the Road Star. (V-Star 1100 applications use the right front coil and require fuel tank removal.) TIP: Long needle nose pliers are useful in removing and re-installing the coil wires. If desired, tach wire loom may be shortened as necessary. Using an appropriate crimping tool, connect the Tachometer wires in the following manner: Cut Shrink Tubing (#9) into two 1″ pieces

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Installation & Tuning Instructions For all Motorcycle Applications

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Filed Under (Tips and Review) by admin on 02-01-2012

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1) Start with a cold motorcycle, and remove the seat (see owners manual for seat removal instructions). 2) Locate a suitable place for your new PowerCard: It is generally velcroed or zip tied under the seat or behind cowling, check for the easiest mounting and wire routing. Often it is easier to place the card in the desired location, and then pull wires from there, rather than connecting the wires and trying to work the PowerCard backward. (In a 2004 Yamaha R6 for example, it is easiest to mount the card, then route connectors one by one through to the engine compartment.) 3) Disconnect the battery ground. Battery may need to be removed to aid in installation (2006 Yamaha R1 for example). 4) Remove the fuel tank and necessary cowlings – many tanks can simply be rotated up and away to allow access to the fuel injector connectors. Secure the tank. Be careful to prevent fuel spills if fuel line removal is necessary – use the quick-disconnect fittings if your motorcycle is so equipped. (see owners manual for tank removal instructions) a. Note: ZX10 installation also requires removal of the stock air box. Unbolt, disconnect fittings, and then turn clock-wise one-quarter turn to remove. Distributed Exclusively by Moss Motors, Ltd.
3 PowerCard®Instructions Injector lead #3 improperly installed (+) 2 1 (-) 4 3 Distributed Exclusively by Moss Motors, Ltd. 5) Connecting the PowerCard harness inline: a. Remove any one factory fuel injector connector from an injector (a flat blade screwdriver or long nose pliers may be used to ease removal). b. Couple the female connector from the PowerCard onto the fuel injector, and plug the male connector into the ECU/factory wiring harness. c. Repeat for the rest of the fuel injector connectors – The order is not important as long as they are installed as they are paired (in and out)

2007-2008 Honda VTX1300C/R/S/T Fuel Valve Diaphragm Replacement Manual

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Filed Under (Honda) by admin on 21-04-2011

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According to Federal law, any affected units in your new or used inventory cannot be sold or leased until they are repaired. Refer to the REPAIR VERIFICATION and REPAIR PROCEDURE sections of this Service Bulletin.
Before you begin the repair procedure, check if the repair has been performed on the unit. See the IDENTIFICATION section of this Ser- vice Bulletin for more details. • If there is a punch mark – No further action is necessary. • If there is no punch mark – You must pro- ceed with the REPAIR PROCEDURE sec- tion of this Service Bulletin. NOTE: Units repaired in the warehouse may not be reflected on iN at the begin- ning of the campaign. For this reason, always check the VIN stamp prior to per- forming this repair. If you have any questions about repair verifi- cation, please contact your DSeM or TechLine at (800) 421-1900, option 9. NOTE: Refer to section 2-7 of the 2003-2008 VTX1300C/R/S/T Service Manual for specific fuel tank removal instructions. 1. Remove the fuel tank using the procedure in the Service Manual. However, do not remove the fuel valve from the fuel tank. 2. Drain the fuel into an approved container. 3. Remove the four screws and diaphragm cover. NOTE: The diaphragm cover is under spring pressure. Do not lose the spring or screws. The countermeasure part has a paint mark near the air vent hole. 4. Replace the diaphragm, spring, cover, and screws with new parts included in the kit. Install the new diaphragm with the plastic retainer facing the diaphragm cover. NOTE: Make sure the air vent hole is facing downward towards the ground. 5. Reinstall the fuel tank using the procedures in the Service Manual. 6. Refill the fuel tank

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HARLEY DAVIDSON NARROW BEACH HANDLEBAR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-04-2011

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INSTALLATION Preparation To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. Retain all seat mounting hardware. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 2. Loosen the fuel tank. Refer to FUEL TANK REMOVAL in the appropriate section (Carbureted or EFI Engine) of the Service Manual. Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a

HARLEY DAVIDSON MINI-TACH WITH SHIFT LIGHT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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INSTALLATION Preparation For EFI models: To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00275a) Follow the instructions found in the Service Manual to purge the fuel supply of high pressure gasoline and remove the fuel supply line. For ALL models, WITH Maxi-Fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. Refer to the Service Manual and follow the instructions given to remove the Maxi-Fuse. For ALL models, WITHOUT Maxi-Fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. -J04106 Gasoline can drain fr om the carb uretor fuel line when disconnected from fuel valve fitting. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00256a) 2. For carbureted models: Turn the fuel supply valve to OFF. Remove the fuel line from the valve. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 3. For ALL models: Follow the instructions in the Service Manual to remove the instrument console from the fuel tank. 4. See FUEL TANK: REMOVAL in the appropriate section (Carbureted or EFI Engine) of the Service Manual for instructions to remove the tank. 5. For all models EXCEPT FLHR or 1986 and later FL Softail models with Chrome Headlight Nacelle Kit (Part Number 67907-96): Follow the instructions in the Service Manual to remove the headlamp housing. For FLHR models, or Softail models WITH the Nacelle Kit: Follow the instructions in the Service Manual and the mini-tach bracket kit (purchased separately) to remove the handlebar shroud. Mini-Tach Bracket Installation 6. For all models except FLHR: Install the mini-tach bracket components per the instructions in that kit. For FLHR models: Follow the instructions in the Service Manual and the mini-tach bracket kit to install the handlebar shroud and bracket components. 7. See Figure 7. Select the rubber isolation gasket (1) from this kit.

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HARLEY DAVIDSON ROAD TECH XM SATELLITE RADIO RECEIVER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-01-2011

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INSTALLATION NOTE Do not use solvent-based chemicals or waxes directly on the plastic or rubber components as they can affect the overall performance and appearance of the plastic and rubber. Models with main FUSE: To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the Service Manual and follow the instructions given to remove the main fuse. Models with main CIRCUIT BREAKER: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) -J03989 1 of 8
Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Refer to Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. Receiver Mounting Bracket Installation When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 2. ALL models: See FUEL TANK: REMOVAL in the appropriate section (Carbureted or EFI Engine) of the Service Manual for instructions to remove the tank. 3. Using a T-27 TORX drive head, remove the two screws that retain the clutch-lever clamp to the handlebar. 4. See Figure 4. Obtain the correct mounting bracket (2) for your vehicle, and two button-head screws (3) and spacers (4) from the kit. Insert the button-head screws into the mounting bracket, through the holes above and below the slot. Place a spacer over the threads of each screw. Insert the screw threads into the holes in the clutch lever clamp removed earlier. 5. Adjust the hand lever position for rider comfort and posture, then tighten the screws to 60-80 in-lbs (6.8-9.0 Nm) . Receiver and Antenna Bracket Installation 6. Obtain the satellite radio receiver (1), antenna bracket (6), and four lock nuts (8) from the kit. Insert the four studs on the back of the receiver through the four holes in the receiver mounting bracket. 7. See Figure 4 for mounted position of the antenna bracket to the receiver mounting bracket. Assemble a lock nut to each of the bottom two studs. Install the antenna bracket onto the top two studs, and assemble a lock nut to each top stud. Tighten the locknuts securely. Antenna Installation 8. Obtain the XM radio antenna (5) and two-sided adhesive tape (7) from the kit. 9. Use isopropyl alcohol to clean the horizontal antenna mounting surface of the antenna bracket, and the bottom (mounting) surface of the antenna. 10. Peel the liner from one side of the tape, and apply the tape squarely to the bottom surface of the antenna. 11. Peel the liner from the exposed side of the adhesive tape on the antenna base. 12. Position the antenna over the bracket without touching the adhesive to the bracket. Center the antenna over the bracket with the antenna cable toward the center of the vehicle. 13. Press the antenna squarely and firmly onto the bracket, and hold pressure for about 60 seconds. After releasing pressure, avoid direct contact with the antenna for about 20 minutes. HARNESS ROUTING AND CONNECTION

ROAD TECH XM SATELLITE RADIO RECEIVER KIT INSTALLATION

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Filed Under (Harley Davidson) by admin on 25-12-2010

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1. Refer to the Service Manual and follow the instructions given to remove the main fuse. Models with main CIRCUIT BREAKER: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) -J03989 1 of 8 Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Refer to Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware. Receiver Mounting Bracket Installation When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 2. ALL models: See FUEL TANK: REMOVAL in the appropriate section (Carbureted or EFI Engine) of the Service Manual for instructions to remove the tank. 3. Using a T-27 TORX drive head, remove the two screws that retain the clutch-lever clamp to the handlebar. 4. See Figure 4. Obtain the correct mounting bracket (2) for your vehicle, and two button-head screws (3) and spacers (4) from the kit. Insert the button-head screws into the mounting bracket, through the holes above and below the slot. Place a spacer over the threads of each screw. Insert the screw threads into the holes in the clutch lever clamp removed earlier. 5. Adjust the hand lever position for rider comfort and posture, then tighten the screws to 60-80 in-lbs (6.8-9.0 Nm) . Receiver and Antenna Bracket Installation 6. Obtain the satellite radio receiver (1), antenna bracket (6), and four lock nuts (8) from the kit. Insert the four studs on the back of the receiver through the four holes in the receiver mounting bracket. 7. See Figure 4 for mounted position of the antenna bracket to the receiver mounting bracket. Assemble a lock nut to each of the bottom two studs. Install the antenna bracket onto the top two studs, and assemble a lock nut to each top stud. Tighten the locknuts securely. Antenna Installation 8. Obtain the XM radio antenna (5) and two-sided adhesive tape (7) from the kit. 9. Use isopropyl alcohol to clean the horizontal antenna mounting surface of the antenna bracket, and the bottom (mounting) surface of the antenna. 10. Peel the liner from one side of the tape, and apply the tape squarely to the bottom surface of the antenna. 11. Peel the liner from the exposed side of the adhesive tape on the antenna base. 12. Position the antenna over the bracket without touching the adhesive to the bracket. Center the antenna over the bracket with the antenna cable toward the center of the vehicle. 13. Press the antenna squarely and firmly onto the bracket, and hold pressure for about 60 seconds. After releasing pressure, avoid direct contact with the antenna for about 20 minutes. HARNESS ROUTING AND CONNECTION NOTE Route the satellite radio receiver harness along the outside of the handlebar, even on internally-wired handlebars. 1. Route the unconnected end of the satellite radio receiver harness as follows: a. Follow the existing wiring from the left-side handlebar switches over to the center of the handlebar. Temporarily bind the harness in place as you route the harness along the handlebar to the center. Do not permanently wire tie the harness to the handlebar at this time. b. Route the wires down through the upper fork bracket (triple clamp), past the steering head, and back along the frame backbone toward the seat. Follow existing wiring where practical. For FLHT, FLHTC, FLHTCU, FLHX models , it may be necessary to remove the inner fairing cap to secure the wires. c. Locate the main harness chassis ground connection on the frame. See the Service Manual for your model and year vehicle for specific location. Remove the ground screw or nut. d. Select the appropriate ring terminal (9 or 10) to fit the ground screw or stud

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